Filtration media for filtering particulate material from gas streams

a technology of filtration media and gas stream, which is applied in the direction of filtration separation, separation process, other domestic articles, etc., can solve the problems of charge dissipation, current limitations, and loss of filtration efficiency in use of air filter media and media manufactured by wet-laying process,

Active Publication Date: 2006-06-29
DUPONT SAFETY & CONSTR INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Electrostatically enhanced air filter media and media manufactured by the wet laid process, more specifically with the use of glass fibers, currently have limitations.
Electrostatically treated meltblown filter media, as described in U.S. Pat. Nos. 4,874,659 and 4,178,157, perform well initially, but quickly lose filtration efficiency in use due to dust loading as the media begin to capture particles and the electrostatic charge thus becomes insulated.
In addition, as the effective capture of particulates is based on the electrical charge, the performance of such filters is greatly influenced by air humidity, causing charge dissipation.
Microglass fibers and blends containing microglass fibers are typically relatively brittle, and thus when pleated, break resulting in undesirable yield losses.
Broken microglass fibers can also be released into the air by filters containing microglass fibers, creating a potential health hazard if the microglass were to be inhaled.

Method used

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  • Filtration media for filtering particulate material from gas streams
  • Filtration media for filtering particulate material from gas streams
  • Filtration media for filtering particulate material from gas streams

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0050] Nanofiber layers were made by electroblowing a solution of nylon-6,6 polymer having a density of 1.14 g / cc (available from E. I. du Pont de Nemours and Company, Wilmington, Del.) at 24 weight percent in formic acid at 99% purity (available from Kemira Oyj, Helsinki, Finland). The polymer and solvent were fed into a solution mix tank, the solution transferred into a reservoir and metered through a gear pump to an electroblowing spin pack having spinning nozzles, as described in PCT Patent Publication No. WO 03 / 080905. The spin pack was 0.75 meter wide and had 76 spinning nozzles. The pack was at room temperature with the pressure of the solution in the spinning nozzles at 10 bar. The spinneret was electrically insulated and applied with a voltage of 75 kV. Compressed air at a temperature of 44° C. was injected through air nozzles into the spin pack at a rate of 7.5 m3 / minute and a pressure of 660 mm H2O. The solution exited the spinning nozzles into air at atmospheric pressure...

example 2

[0052] An SN structure was made as described in Example 1, but at a higher basis weight of the nanofiber layer. The resulting structure was challenged at various particle sizes for filtration efficiency and pressure drop, and the results are given in Table 1.

TABLE 1NanofiberNanofiberPressureFrazier airEx.diameterbasis weightEfficiencyDroppermeabilityNo.(nm)*(g / m2)(%)(mm H2O)(m3 / m2 / min)1341 / 387369.93.7372374 / 3625856.422

*first measurement / second measurement

example 3

[0053] A filtration medium having an SN structure was formed as in Example 1 by depositing a nylon nanofiber layer containing solvent, having a basis weight of about 3 g / m2 on a Finon C 3070 spunbond PET scrim having a basis weight of about 70 g / m2. The average diameter of the nanofibers was about 400 nm. The nanofiber web was collected on the scrim under a collector vacuum pressure of 60 mm H2O to form the composite SN fabric, and the composite fabric was passed through a dryer at 110° C. and at a vacuum pressure of 20 mm H2O. The composite fabric was pleated to form a pleated filter medium. The solvent-bonding process resulted in a good bond of the nanofiber web to the scrim with no delamination and good abrasion resistance of the nanofiber layer to hand rubbing of the pleated medium. The pressure drop and the efficiency of the filtration medium before and after pleating are listed in Table 2.

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Abstract

A composite fabric formed by depositing a web of nanofibers electroblown from a first polymer onto a first support web comprising fibers of larger average diameter than the nanofibers spun from a compatible material, in the absence of an adhesive between the webs, and solvent-bonding the webs together.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to composite nonwoven fabrics suitable for use as air filtration media, for filtering particulate material from fluid streams. [0003] 2. Description of the Related Art [0004] Filter media typically utilized for HVAC air filters that perform at efficiencies less than 99.97% at a 0.3 micron challenge are either glass, cellulose or polymer based. Filters made with media in this performance range are typically referred to as “ASHRAE filters” since the American Society of Heating, Refrigerating and Air-Conditioning Engineers writes standards for the performance of filter media in such applications. Polymer based filter media are typically spunbond or meltblown nonwovens that are often electrostatically enhanced to provide higher filtration efficiency at lower pressure drop when compared to glass or cellulose media manufactured by a wet laid paper-making process. [0005] Electrostatically enha...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B01D46/00D04H3/16
CPCB01D39/1615D04H13/007B01D39/18B01D46/22B01D46/521B01D46/546B01D2239/0681B01D2239/10B01D2273/28B01D2275/10B32B5/022B32B5/024B32B5/26B32B2250/20B32B2262/0261B32B2307/544B32B2307/546B32B2459/00D04H3/16D04H13/002B01D39/163D04H13/00D04H1/4374D04H1/559D04H1/728B01D2239/025
Inventor LIM, HYUN SUNGSUH, HAGEUNWISEMAN, B. LYNNE
Owner DUPONT SAFETY & CONSTR INC
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